Thermal Data Assimilation into a Real-Time Digital Twin of Liquid-Cooled Power Electronics via an Edge-Resident Particle Swarm Framework

The next generation of naval and defense systems will strain current naval ship cooling systems. Throughout its life-cycle, this strain will alter the behavior of the physical system, and any virtual representation of the system will become outdated due to component aging. Digital twins are a trending tool that can assimilate real-time sensor data to tailor a virtual representation to its physical counterpart. The online faithful virtual representation of the physical system provided by digital twins can be used for real-time system optimizations and proactive fault detection, diagnostics, and control adjustments, alleviating the stress of component aging. To support these complex power systems throughout their lifecycles, data-driven solutions for digital twin tuning will become essential. This paper investigates the application of a parameter-tuning digital twin framework to enhance the performance of a multi-physics model. The digital twin framework comprises a digital twin tuning scheme, a physical testbed designed to emulate the cooling system of a ship, and a multi-physics representation of that system. The digital twin tuning scheme leverages a swarm of particles and online sensor data to evaluate permutations of parameters to update the digital representation periodically. The digital twin framework was applied to a physical system to provide experimental data results demonstrating the usefulness of the tuning system. The physical system was designed and constructed to emulate the heat generation and dissipation from 6 liquid-cooled power converters under loads ranging from 10–15 kW at 99% efficiency. Two scenarios were applied to evaluate the performance of the digital twin framework. Results demonstrate that the digital twin framework can adapt to system changes in real-time and improve the accuracy of the related virtual representation by more than 90% when measured at four points of the system under test.